Heavy duty container for bulk material



S p 1956 c. D. FALLERI Y, 1

' HEAVY DUTY CONTAINER OR' BULK; MATERIAL Filed May 3, 1954 I "4 Sheets-Sheet 1 6.4 M wJf/ukmr Sept. 11, 1956 c. n. FALLERT HEAVY DUTY CONTAINER FOR BULK MATERIAL 4 Sheeis-Sheet 2 Filed May 3, 1954 Sept. 11, 1956 c. D. FALLERT HEAVY DUTY CONTAINER FOR BULK MATERIAL 4 Sheets-Sheet 3 Filed May 5. 1954 FIGJZ.

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Sept. 11, 1956 c:.- 12 FALLYEVRTW HEAVY DUTY CONTAINERFOR BULK MATERIAL 4 Sheets-Sheet 4 Filed May 3. 1954 I M w w k I HEAVY DUTY CONTAINER FOR BULK MATERIAL Clifford D. Fallert, St. Louis, 'Mo., assignor to Crown Zellerbach Corporation, San Francisco, Calif a corporation of Nevada Application May '3, 1954, Serial No. 427,163 l'Claim. (Cl. 22923) This invention relates to relatively large heavy duty containers for packing, shipping and storing relatively large quantities of bulk commodities which require positive protection from sifting and leakage and from contamination from extraneous matter. Containers employing this invention may be constructed of solid fibreboard, corrugated fibreboard or any other suitable material.

More specifically, the container comprises a bottom tray with continuous upstanding walls integral with a flat bottom panel, the inner and outer faces of the upstanding tray walls being firmly telescoped between lower end portions of inner and outer, open-ended, tubular sleeves, the bottom edges of the inner sleeve being in abutting relation with the inner face of the bottom panel of the tray, and the bottom edge of the outer sleeve being in substantially coplanar relationship with the outer face of the bottom panel. The upper portion of the container may be provided with a telescoping cover member having a top panel and depending side walls positioned so that the upper edges of the tubular sleeve members abut the panel.

Containers employing this invention may be designed to carry, for example, five hundred to two thousand pounds of free flowing bulk commodities, i. e. bulk commodities in granular, pellet or powder form and often range in size from 24" x 24" x 30" to 40" x 40 x 60". The relatively large containers of this type are to be distinguished from types designed for shipping refrigerators, water heaters and other self-sustaining items wherein the principal function of the container is to protect the exterior surfaces of such articles. The large unit quantities of the free flowing bulk commodities hereinbefore mentioned exert a substantial outward and downward force on the walls and bottom structure of the container. Consequently, it is unexpected that containers constructed of relatively light, foldable materials such as fibreboard and the like can be used successfully for the purposes described.

Many of the bulk materials, for example, flour, chemical pellets, grain and the like, have heretofore been shipped in cylindrical fibreboard or metallic drums usually having a maximum capacity of from 50 to 300 pounds depending on the density of the commodity. The use of containers of the present invention results in important economies. In the first place, the cost of containers adapted to carry quantities of a thousand pounds or more of bulk material of the kind described is substantially less than the cost of the five or more cylindrical drums usually employed for this purpose. Furthermore, containers of the type embodying this invention are easier to handle with modern high-speed material handling equipment. The containers may be, and usually are, palletized so that they may be stacked two, three or even four high. Users of the container have found that these and other economies result from their use.

An object of this invention is to provide an inexpensive, sift proof and contamination proof container for relatively large quantities of bulk materials which will provide positive protection from contamination by extraneous matter during transportation and storage.

A further object is to provide containers which may vary in size, for example, from 24" x 24" x 30 to 40" x 40" x 60 or similar dimensions for shipping a wide variety of bulk commodities.

Patented Sept. 11, 1956 These and other objects will be apparent upon a further understanding of the invention as described and set forth in the following description.

Fig. l is a perspective view of a pair of inner and outer collapsed tubular sleeves which may be employed in a preferred embodiment of the invention;

Fig. 2 is a perspective view of a pair of blanks which may be erected into top and bottom closure caps;

Fig. 3 is a perspective view of a closure cap illustrated in erected form;

Fig. 4 is a perspective view of a wooden pallet of a type adapted to support containers embodying this invennon;

Fig. 5 is a front elevation of a pallet member shown with the bottom closure cap in position;

Fig. 6 is a perspective view of the inner tubular liner shown in erected condition;

Fig. 7 is a front elevation of a supporting pallet, the bottom closure cap with the inner tubular liner in place;

Fig. 8 is a view through section 88 of Fig. 7;

Fig. 9 is a front view of the outer tubular sleeve being telescoped onto the inner tubular sleeve;

Fig. 10 is a vertical view through section 1010 of Fig. 8;

Fig. 11 is a front elevation of the container of Fig. 9 with the inner and outer sleeves in place;

Fig. 12 is a horizontal view through section 12-12 of Fig. 11;

Fig. 13 is a vertical view through section 13-13 of Fig. 12;

Fig. 14 is a front elevation of a loaded container shown with the top closure cap in position, and the top corner portion cut away to illustrate the side wall construction of the completed container;

Fig. 15 is a vertical fragmentary view through section 1515 of Fig. 14;

Fig. 16 is a front elevation of a loaded container shown with banding or strapping means secured in position; and

Fig. 17 is a perspective view of the loaded, palletized container employing this invention being transported by a standard fork lift truck illustrated by the dashed lines.

The embodiment of the invention illustrated in the accompanying drawings comprises essentially an inner sleeve A, a bottom closure cap B, an outer sleeve C and a top closure cap D. As best shown in Fig. 1, the inner sleeve A is provided with side walls 26 connected together along corner scores 21. A suitable length of tape 22 or any other desired means of securing the ends of the inner sleeve blank together is provided.

Similarly, the outer sleeve C is also provided with side walls 23 connected together along corner scores 24. The abutting free edges of the blank of the outer sleeve C may also be secured together by a suitable length of tape 25. For reasons which will become apparent later in the specification, and as shown in Fig. l, the walls 20 of the inner sleeve A are slightly narrower in width than the side walls 23 of the outer sleeve C. In the particular embodiment illustrated, the height of the side walls 20 of the inner sleeve is slightly less than the side walls 23 of the outer sleeve for reasons set forth later in the description.

The bottom closure cap B and the top closure cap D shown in Fig. 2 are each provided with side flanges 26 foldably connected to the bottom closure panel 27 and the top closure panel 28 respectively, along side scores 29. Triangularly shaped flaps 30 are defined in part by extensions of the side scores 29.

A method of assembling and erecting the embodiment of the invention illustrated is to fold the side flanges 26 of the bottom closure cap upwardly about the adjacent side scores 29. The triangular end flaps 30 are then folded inwardly into flatwise contacting relationship against the adjacent inner or outer face of the adjacent upwardly disposed side flanges 26. In this position each triangular flap 30 is secured to the adjacent side flange 26 by stitches 31. However, if desired, other securing means, for example, glue or tape, may be employed. The tray thus formed has, in effect, a continuous, substantially rigidly disposed side flange construction with reinforced corner portions.

One suitable means facilitating the handling of containers of the sizeand weight of the embodiment illustrated is to employ a pallet or skid member constructed of suitable material. A particular style of pallet 33 is illustrated, although any suitable supporting means may be employed. The pallet may be constructed of any satisfactory material, for example, wood. The pallet is provided with heavy supporting runners 34 to which are secured cross slats 35. The erected, bottom closure cap B is then placed on the pallet 32 as shown in Fig. 5. The inner sleeve A is then erected to rectangular, tubular shape as shown in Fig. 6 and is then placed within the previously positioned bottom closure cap B as shown in Fig. 7, with its lower end edges in abutting relation with the inner face of closure panel 27. It is preferable that the dimensions of the inner sleeve A and the bottom closure cap B be such that the inner faces of the side flange thereof firmly contact and engage the outer surfaces of the adjacent side walls 20.

The outer sleeve C is then telescoped over the previously erected inner sleeve A as illustrated in Fig. 9.

The sleeve C is forced downwardly until the inner faces of the lower margins of the side walls 20 are in firmly contacting relation with the side flanges 216 of the bottom closure B and the lower end edges of the sleeve C are in coplanar relation with the bottom closure panel 27. In effect, the lower portions of side walls 23 securely encircle and reinforce the side flanges 26 of the bottom closure cap. Also, as illustrated in Fig. 13, the placement of the inner sleeve A within the closure cap and the outer sleeve C around the outer surfaces of the side flanges 26 provides an effective seal which prevents leakage of the contents. The sleeve members are in no manner secured to the bottom closure cap B in the embodiment described. This feature is important in large, heavy duty containers which are often erected and assembled at the loading station. In the embodiment illustrated it is preferable that the inner sleeve A be dimensioned so it is slightly shorter in height (by a distance equal to the thickness of the bottom panel 27), than the outer sleeve C. In this manner, in the erected container as illustrated in Figs. 14 and 15, the top edge of the inner sleeve A is in horizontal alignment with the top edge of the outer sleeve C.

The container then may be loaded with the material. As indicated hereinbefore, the heavy-duty container described is particularly adapted for relatively heavy, free flowing, bulky contents. The contents ordinarily cause the walls of the container to bulge outwardly as most plainly shown in Figs. 14 through 16. The side walls 20 are forced tightly against the inner faces of the side flanges 26 which in turn tend to press firmly against the inner faces of the side walls 23 of the outer sleeve C. An even tighter, sift proof seal is thus provided. Due to the flexibility of the side walls 20, the outward force exerted by the contents often actually forces them into contacting relation with the adjacent side walls 23 of the outer sleeve C. In that manner, each component in succession acts to provide additional reinforcement for the adjacent parts of the container as additional strength is required. A top closure cap D having downwardly depending side flanges 26 may be placed over the outside faces of the side walls 23. The top closure cap D will, in effect, tend to maintain the top portion of the container in proper position and alignment.

The construction of applicants bottom structure not only reinforces the peripheral side flanges 26 of the bottom closure cap B, but the frictional contacting engagement between the lower portions of the side walls 20 and the side walls 23 engage the bottom closure cap B to strengthen and prevent undesired movement thereof downwardly with respect to the inner and outer sleeve members. The frictional engagement between the memhers is brought about by the dimensioning of the component parts as well as the outward thrust of the contents. The firmly abutting contact at 32 of the inner side walls 20 also effectively contributes to the leak-proof seal. Furthermore, the construction of the invention provides a smooth unobstructed exterior bottom portion so that there is no possible chance for dust or other foreignmatter to work its way into the container.

After the assembled container is loaded and top closure cap D is in position, it may be made ready for shipment by means of straps or banding means 36 which, if desired, may be positioned to extend underneath the pallet member 33. The straps 36 or other suitable banding means provide additional reinforcement to the container. However, in many instances, it has been found that the container itself has sufficient strength to provide adequate protection to the contents. In these instances, the top closure cap D may be taped or glued into position.

To further illustrate the size of one embodiment of the container as well as a particular means of transporting the container, Fig. 17 shows a completed container and pallet being engaged and lifted by fork elements 37 of a lift truck 38. In this manner containers embodying the disclosed invention carrying large amounts of heavy materials may be readily moved from place to place with a minimum of manual assistance.

The shape and dimension of the container may be varied, for instance, a container of hexagonal or octagonal cross section may be employed. Also, the closure caps B and D may be modified to other types of construction which provide a conterminous side flange construction. These and other modifications fall within the intended limits of the invention claimed in the following claims.

What I claim as my invention is:

A tall heavy duty rigid rectangular container for shipping and/or storing material therein comprising a relatively shallow collapsible rectangular tray having a flat bottom with an upstanding rectangular wall thereabout, the rectangular wall comprising upstanding flanges coextensive and integral with the edges of the tray bottom, the flanges being connected together by extensions from the ends thereof secured to adjacent marginal portions of the respective flanges adjacent the corners, inner and outer open-ended collapsible sleeves many times greater in height than the height of the tray wall, the sleeves each being interiorly unobstructed throughout their lengths and in sliding telescoped relation one with the other, the lower portions of the sleeves being in parallel relationship with each other, the lower portion of the inner sleeve being disposed in snug contacting relation with the inner surface of the upstanding wall and with the lower end edge thereof in contactim relationship with the adjacent inner surface of the flat bottom, the outer sleeve having its lower portion snugly engaging the outer surface of the upstanding wall and with its lower edge substantially co-planar with the exterior surface of the flat bottom, the wall of said tray being thus clamped and secured between the inner and outer sleeves solely by friction, and the upper edges of said inner and outer sleeves being substantially co-planar.

References Cited in the file of this patent UNITED STATES PATENTS 1,430,149 Bliss Sept. 26, 1922 l,911,339 Andrews May 30, 1933 1,959,193 Boeye May 15, 1934 2,534,010 Frye Dec. 12, 1950 2,634,038 George Apr. 7, 1953 2,665,806 Budd Jan. 12, 1954 

